Felt base floor covering and method of making the same



NovQ 11, 1958 I s'. A. COHEN ETAL 2,860,071-

FELT BASE FLOOR COVERING AND M E'I'HOD OF MAKING THE SAME I Filed Oct. 21.195;

PRINT PRINT COATING CONTA INING- VINYL CHLOR/0E VINYLIDENE CHLORIDE COPULYMER II II II II I II II II II II II II II I I II II I II II FELT BASE SHEET SEAL CORT N INVENTORS a I ml 11. 005611 BY l'masi R. 1W9! KWKKM ATTORNEY 7 improved vinyl resin 2,860,071" r FE BASE 1100a COVERING AND METnoDbF Samuel A. Cohen, Auburn, "and Ernest R. Mower, Winthrop, Maine, assignors to Bonafide Mills, Inc., Lisbon,

k Maine, a corporation of Maine Application October 21,1953, s un-1510.335 11 Clai1ns. (Cl.117; -72) This invention relates to a felt .ba'se floorcovering and I more particularly to animproved feltbase floor covering t meme I face-coating a saturated felt sheet with a coating paint by means ofa knife orother suitable apparatus to' provide what is known 1n the art as a seal coat. Following the application of the seal coat to the saturated felt backing, the result ng material is then passed under a series of print blocks through a blockprinting apparatus. The blocks are passed acrossrolls in containers of 'paint of their respective colors, and various designs are applied by means of the multiple blocksto the coated felt base. Following the application of the decorative coating, the material is suspended inflsto'ves to dry the paint film. The paints employed, because ofthe manner in which" they are applied, are called fprint paints; and in the art the goods are known as printed felt base floor coverings.

Various coatings have been used for decorating the surface of a seal-coated saturated felt; Generally speaking, these coatings are conventional print paints containing the desired color pigment and a drying oil-resin typeve-v hicle. These drying oil-resin type vehicles have found wide use in the production of printed felt base goods.

It has heretofore been recognized that vinyl resins impart desirable properties to the decorative wearing surface layer of printed felt base goods, and various attempts to'utilize vinyl resins insuch coatings have heretofore met with little success primarily because ofthe fact that difficulty has been experienced in securing the necessary strong bond to the underlying seal coat, particularly of the types which have heretofore been generally used, and

which have comprised oleoresinous base coatings.

One attempt to solve'the problem is illustrated in thepatent to Hazeltine, No. 2,624,682, wherein it is proposed to embody from 20 to 50% of. a rubberlike component in the seal coat together with a vinyl resinous re inforcing agent. The print paint comprises an organosol consisting of a vinyl resin or copolymers thereof sus-' pended as finely divided particles in "a plasticizer and nonsolvent hydrocarbon. The process required to produce the Hazeltine product involves the heating of the product United j we have discovered that the required bond between a vinyl print. coating and the underlying seal coat, and, particularly an underlying .seal coat of an oleoresinous base, 'mayfbe secured by embodying in the print paint a solution of a vinyl chloride-vinylidene chloride copoly- .nier containing at least 20% and preferably substantially 40% ofvinylidene' chloride. Such a product is obtainable under the trade name,. Geon Resin 200 x20, manu-- factured--by Goodrich Chemical $30. In practice other vinyl polymers may be usedwith {the Geon 200 x 20 including- Ivinyl chloride-vinyl (acetate copolymer, polyvinyl chloride, vinylchloride 'vinyl acetate copolymer' interpolymerizedswith a dibasic acid, such as maleic an.-

.hydride, vinyl chloride-vinyl chloride copolymer containing ahydroxy group. Other vinyl resins, such as polyvinyl butyral, vinyl acetate, copolymers of vinyl chloride and acrylqnitrile as well as certain other vinyl chloridevinylidenel'c'opolymers formulas may be used withYGeon 200-1120. Although a polyester type of plasticizer is, shownabove, other plasticizers may. also be used alone or ,in combin atiomf such as 'dioctyl phth alate dibutyl phthalate, butyl benzyl phthalate, tricresyl phosphate, triphenyl phosphate, alkyl aryl phosphateand the like.

The solvents shown in the preferred example vmay also be varied. Xylol, toluolor aromatic petroleum solvents mayals'obe'v used for part of the ketones. Other ketones, such as methyl ethyl ketone and acetone and the like may be used.

,In producing av print paint in accordance with the presentinvention embodyingan oleoresinous vehicle to which vinyl polymers are added in such a manner as to to 300-350 F. in order to effect fusion of the individual 7 particles into a film.

The present invention seeks to provide a superior prlnted felt base goods in which any usual or preferred form the components. I

The invention will further be understood by reference to the accompa ying drawing wherein sole figure is illustrativeofa'p'referred embodiment. 11

be compatible therewith, we may prefer to produce a body vehicle which when pigmented comprises the base for the production of the present print paint. The body vehicle may have the following formulation:

BODY VEHICLE 1 Example I 850# rosin 62.5 gals. soya fatty acids 563 gals. linseed oil I Raise heat to 400 F. turn heat off andadd 250# of phenol formaldehyde resin (tertiary butyl phenol type) Wait 20 minutes, begin to reheat and add 200# pentaerythritol :Heat to 575 F. andhold to at least a Z to Z2 .viscosity to an acid number below 10. Cool and add gallons of heavy bodied leaded linseed oil (appr. Z-3) containing appr. 1/2 to 1% litharge g 198 gallons mineral spirits 69# liquid lead drier (24% Pb as metal) l5 manganese drier (6% Mn as metal) Example II 170 lbs. linseed fatty acids 233 lbs. Acintol FA (refined tall oil) Heat to 350 F., and add 31 lbs. pentaerythritol Hold hour @400 F., then add I 100 lbs. Epon Resin 1001 1 Heat to 500 F., hold hr. Heat to 550 F., hold 2 hrs. Cool and add lbs. mineral spirits A 2lbs. liq. Pb 24% 0.65 lb. liq. Mn 6% As alternative compositions of the body vehicle we. may use tall oil as a substitute'for the fatty acids in the foregoing formulation, and in addition hempseed, perilla,-

fish oil, safiiower, walnut and the like may beused, either individually or in various combinations as may be found desirable and in varying proportions. In place of linseed oil other siccative drying oils may be used, such as soya, hempsee'd, perilla, fish oil, walnut, dehydrafedicastor, oiticica, China-wood, etc. The siccative drying oils may be used alone or in, various combinations. Sic'cative dry; ing oils may also be replaced by fatty acids or the fatty. acids may be 'used in place of the drying oils adjusting formaldehyde resins of either the oil' reactive or oil and;

heat reactive type, modified phenolic resins of thephenol modified type and oil extended type. i

Other resins, such as petrex resins, may be used. Petrex acid isv a synthetic resinous polybasic acid of terpene origin, and is used in the manufacture of heat setting alkyd resins. Another resin which may replace the phenolic resin partially or entirely is the synthetic resin whose fundamental ingredient is carbic anhydride. The carbic anhydride is produced by the reaction of cyclopentadiene and maleic anhydride. This adduct in turn is reacted with a polyhydric alcohol and a fatty acid to form a carbic resin. Resins of these types are heat reactive or oil reactive and' oil soluble.

Other epoxy type resins may also be used which are reaction. products resulting from the reaction of a mixture of a dihydric phenol with epichlorhydrin or glycerol dichlorhydrin. Melamine or urea resins which are compatible, with the oleoresinous body vehicle may also be used.

In producing the present print paint, we may prefer to produce a base grind of pigment, heavy bodied linseed oil and the body vehicle, as above described, ground through a 3-roll mill or similar equipment, and one formulation for producing a base grind for a white-base print paint as follows:

112 Titanox RCHTX (titanium calcium pigment) .64 calcium carbonate 12 'heavy bodied linseed oil 160 above body vehicle -It is understood that the white base may be modified with other hiding power pigments, such aslitliopone, titanated lithopone, zinc sulphide, titanium dioxide, let

downtitanium pigments, such as calcium titanium pigment, barium titanium pigment, high strength lithopone, zinc oxide and the like.

Modified formulas for the base grind are as follows:

800 lbs. Titanox RCHTX 450 lbs. calcium carbonate 125 lbs. zinc oxide 120 lbs. melamine resin 650 lbs. body vehicle 800 lbs. Titanox RCHTX 450 lbs. calcium carbonate 125 lbs. zinc oxide 120 lbs.'melamine resin 25 lbs. long; oil alkyd resin 62.5 lbs. body vehicle zso lbs. titanium dioxide 1000 lbs. calcium sulphate 125 lbs. zinc oxide 120 lbs. melamine resin 650 lbs. body vehicle Formulas for the vinyl solutions are of the following character:

VINYL CHLORIDE-VINYLIDENE CHLORIDE I COPOLYMER SOLUTION I 100# vinyl chloride-vinylidene chloride copolymer(Geon Resin 200 x 20, "G00drich Chemical Co.) 186# diisobutyl ketone VINYL POLYMER SOLUTION 10o#- vinyl polymer (G eon Resin 400x 74 (Goodnich;

Chemical Co.) i 300# methyl isobutyl ketone I 100# Geon' 205' (vinyl chloride-vinyli'dene chloride polymer) 400# methyl isobutylketone I00#- Vinylite VYHH1'(viny1 chloride-vinyl acetate co? polymer) 400# methyl isobutyl ketone acetate copolymer) 400# methyl isobntyl ketone For best results we have. utilized. a mixedvinyle solution: according to thefollowing formulations:

MIXEDVINYL SOLUTION (PREFERRED) Geon' 200 x 20 solution#l 46# vinyl polymer solution'400 x 74-#II 1 4#"P'araplex G62 (polymeric type plasticizer) I# stabilizer The amount of vinyl, polymer solution 400 x. 74-#I'I: shown in the preferred mixed vinyl solution may be replaced with a similar quantity of III, IV, and V respectivel-yf Little or no stabilizer may be used. If stabilizer is to be used. barium cadmium laurate, barium cadmium. rici-noleate, strontium zinc laurate, barium ricinolea-te, cadmium 2 ethyl hexoate or, other barium or calcium. compounds; dibasic lead stearate, dibasic lead phosphite, normal lead salicylate or other lead compounds may be. used. Organic tin compounds may also be used. These stabilizers may be used with epoxide type resins if desired.

PRINT PAINTS lbs. base grind 6 lbs. body vehicle 40 lbs. mixed vinyl solution 100' lbs. basegrind 53 lbs. mixed vinyl solution 100 lbs. base grind Slbs. long oil alkyd resin 35 lbs. mixedvinylsolution.

Lower ercenta e 0!? viii lid n m 1-- Geon 200 x 20. g Y content h n.

40.0 methyl isobutyl ketone The above are preferred formulations 'The extender pigments can be varied as well as the hidingpower pigments. The melamine resin maybe omitted, but we find that the introduction of melamine resin permits a faster cure as well as imparting additional alkali resist- 5 ance and wear. The percentage may also be varied in the formulas. 1 y a 1 I The percentage of vinyl resin tothe oleoresinous binder may bevaried. The above formula shows 25% vinyl resin and 75% oleoresinous binder. Formulas have been successfully produced using higher or lower percentages ranging from 5% vinyl resin to50% 'vinylresinL Although a conventional oleoresinous seal coat may be used to obtain satisfactory bond with the print paint .we have also found that a sealcoat using a polyvinyl acetate emulsion as a binder in place of the oleoresinous binder is not only excellent forbond but offers better sealing flexibility and toughness.

TYPICAL EXAMPLE OF POLYVINYL'ACETATE PAINT Clay 50. 1 Red slate 1 3 0 Polyvinyl alcohol (8% soln) 50 Darvan #1 20% soln) r. 18 Water I 99 Polyvinyl acetate (55% solids) 146 Plasticizer r 20 Sodium salt of polymerized alkyl-aryl sultonic acid. 3O

Pr0cess.Add clay and red slate to polyvinyl alcohol solution, Darvan solution, andwater to produce slurry. Mix plasticizer with polyvinyl acetate, add to slurry and grind. The polyvinyl acetate paint may be produced in a conventional paint three-roll mill, pebble mill, or other i type of grinding equipment. ,0

This seal coat is preferred not only for the oleoresinousvinyl binder but also for the 100% vinyl binderlshown below. This seal coat differs from Hazeltine as we do not use a 'rubberlike. component admixed with a vinyl reinforcing agent for tackifying.

The polyvinyl acetate maybe plasticized with a conventional. chemical plasticizer, and the normal type of extender, such as red slate flour, calcium carbonate, clay, magnesium silicate, aluminum silicate, mica, may be used. The vinyl print paint thus far described preferably has an oleoresinous vehicle, and we have discovered that for some purposes by utilizing a vinyl resinous composition embodying a vinylidene chloride content of from 20 to 40% vinylidene chloride it is possible to producea satisfactory vinyl print paint which will bond satisfactorily to the conventional seal coats, and after the solvents have been evaporated and the composition cured in the usual manner the flooring is readyv for use without requiring fusion of the resins to form the vinyl paint film. The preferred formula containing no oleoresinous vehicle is as follows:

VINYL PRINT PAINT (VI YL POLYMER SOLUTION) Example I 916.0 Geon 400 X 74 dissolved in 48.0 methyl isobutyl ketone 40.0 Neolyn 35 (alkyd resin) dissolved in} 12.0 Paraplex'G-fii. (polyester-epoxy type) 3.0 Mark M (barium cadmium stabilizer plasticizer) 60.0 Atomite CaCOa O 20.0 Titanox RCHTX (titanium-calcium pigment) 20.0 color pigment (VINYL CHLORIDE-VINYL VINYLIDENE OOPOLYMER SOLUTION) I y 44.0 Geon 200 X 20 dissolved in} 82.0 diisobutyl ket-one 1 Example 11 21.0 G'eon 400' x 74 dissolved my 62.0 methyl isobutyl ketone' 20.0 Neolyn 35 dissolved in 20.0 methyl isobutyl ketone 12.0 Paraplex G-62 (polyester epoxy type) 3.0 Mark M (barium-cadmium stabilizer) 70.0 atomite O 20.0 titanium dioxide 10.0 color pigment VINYL CHLORIDE-VINYL VINYLTDENE ooPoLYM'ER 59.0 Geon 200 X 20 dissolved m 110.0 dnsobutyl ketone i Blend solution A and solution B, then add 0 in order. After homogeneous mixture is obtained, grind over a 3-roller'mill twice and then thin with solution 1). I I p From the description of the compositionsof the present vinyl print paintand the methods of making thesame, it will be observed that the'vinyl resins in our print paint are completely dissolved andare, therefore, solutions not organosols. No fusion is necessary. aThe solvents are evaporated, and the flooringis ready for use. We prefer, however, to use a hot air system which is at approximately 150-170" F. to remove the solvents in Stabilizers other than the type'above may be used.

:The types containing lead, strontiumand "tin'alo'ne or in combination may be used for both heat and light stabilization.

Other solvents, plasticizers, pigments and extenders as shown in thetvinyl-oleoresinous section may beused.

. vNeolyn 35 is a rosin derived alkyd material and is preferred because it is the'most polymeric and has the highest melting point. However, other grades of Neolyn may be used."

I Neolyn may be replaced with polymerized rosin, maleate esters, modified rosin esters, modified maleic resins,

rosin modified maleic gly-cerides, or nitrile rubbers.

In order to substantiate our claims for a floor covering with better performance, abrasion tests, scrubbing tests and alkali tests were made on the floor coverings contain; ing vinyl resins as against the regular printed felt base floor covering.

DRY ABRASION RESISTANCE This test is run with the Tabor Abraser Model 13-4010 with the vacuum pickup. A four inch by four inch specimen is cut from the floor covering to be tested. This specimen is mounted on the turntable in the conventional manner without the use of the rim. For this test abrasive wheels are used, each loaded with a 1000 gram weight. The instrument is turned on in the standard fashion and allowed to run until the coated asphalt felt shows through the coating over an area in the path cut by the abrasive wheels. The number of cycles indicated on the counter of the machine is recorded as the Wear cycles of the specimen tested.

ALKALI RESISTANCE There are two solutions required for this test. 1% and 5% solutions of sodium hydroxide in water are applied to the floor coating in test as follows: 5 drops of each solution are applied with a medicine dropper to the surface of the floor covering and immediately covered over with a lab watch glass. These solutions are allowed to remain in contact with the surface of the floor covering for a period of 2 hours. At the end of the test period the watch glasses are removed and the solutions wiped off with a piece of soft flannel. Immediately after this the test specimen is rinsed with clear, cold water. The condition of the area contacted by the solutions is noted.

SCRUBBING RESISTANCE This test is run with a nylon bristled brush, weighted ,7 with approximately 2 pounds of lead. The brush is driven by the arm of a vacuum type windshield wiper. The surface of the floor covering in test is smeared with a scrubbing compound and the brush allowedto work this compound back and forth across the test specimen.

The scrubbing compound is manufactured as follows:.

20 grams of Fels Naphtha Soap is dissolved in 180 grams of hot water. To this is added 20 grams of Oakite and 300 grams of Old Dutch Cleanser. This mixture is thoroughly agitated to produce a smooth, creamy consistency. During the period of the test frequent additions of this scrubbing compound should be added to the surface of the'material in test. The end point is reached when sufi'icient coating has been removed to allow the coated felt to show through the surface. Very small breaks, such as would'be accounted for .by high spots can be disregarded. Failure is that point where very definite break-through is indicated by progressive lengthening of the abrasion lines.

' AVERAGE TEST RESULTS oleoresinous binder in a solvent with from 5% to 50% by weight of a solution of a vinyl resin in a solvent, and then subjecting the 'product to moderate heat substantially below 300" F. to evaporate the solvent and effect curing of -t'h'e' non-vinyl'components without fusing the vinyl resin.

7; The method as defined in claim 6 in which the evaporation of the solvent and the curing occurs at a temperature-of from 70'-'200 F.

.8. 'The method of making a printed felt base sheet comprising the steps of applying to a felt sheet at least one seal coat and then applying to the seal coat a coating composition comprisinga mixture of a solution of an oleo' res'inous binder in a'solvent with from 5% to 50% by weight of a solution of a vinyl chloride-vinylidene chloride copolymer in' a solvent, and then evaporating the solvents at temperatures Substantially below 300 F. and below the'usual fu'sion points of vinyl copolymers.

9. The method of making a printed felt base sheet comprising the steps of applying-to a felt sheet at least one Alkali Taber Scrub Conventional Printed Felt Base 1,400 2,300 Good Fair-Poor.

Floor Covering. (MOO-1,700) oleoresinous Vinyl Printed Floor 5,000 Excellent Good.

Covering. (1,8002,400) High Vinyl Printed Floor Covering.. u 10,'000 'Excellent Excellent. I

While the present invention is particularly useful as a' printed felt base sheet for use as a floor covering it will be understood that the sheet may be used for other purposes, such as a wall covering and for application to other surfaces. Having thus described the invention, what is claimed is: 1.The method of making a printed felt base sheet comprising the steps of applying to a felt sheet at least one seal coat, then applying to the seal coat a ,print paint coating composition containing from 5% to 50% by weight of a vinyl resin solution including a vinyl chloride vinylidene chloride copolymer having a vinylidene chloride content of at least and then subjecting the product to moderate heat substantially below 300 F. Without fusing the vinyl resin.

2. The method as defined in claim 1 wherein said print paint coating composition includes a solution of an oleoresinous binder.

3. The method as defined in claim 1 wherein said print paint coating composition includes a solution of resinous binder materials in addition to said vinyl chloride-vinylidene chloride copolymer.

4. A printed felt base sheet produced by the method defined in claim 1.

'5. The method of making a printed felt base sheet comprising the steps of applying to a felt sheet at least one seal coat, then applying to the seal coat a print paint coating composition comprising a mixture of a base material containing a pigment and a solution of oleoresinous binder in a solvent with from 5% to 50% of a solution of a vinyl resinous material in a solvent, said vinyl resinous material including a vinyl chloride-vinylidene chloride copolymer having a vinylidene chloride content of at least 20%, and then subjecting the product to moderate heat substantially below 300 F. without fusing the vinyl resin.

6. The method of making a printed felt base sheet comprising the steps of applying to a felt sheet at least one seal coat and then applying to the seal coat a coating composition comprising a mixture of a solution of an seal coat and then applying to'the seal coat a coating com position comprising a mixture of a solution of an oleoresinous binder in a solvent with from 5% to 50% by weight of a solution containing a vinyl chlorlde-vinylidene chloride copolymer and at least one other vinyl resin, and then evaporating the solvents at temperatures substantially below 300 F. and below the usual fusion points of vinyl copolymers.

110. The method as defined in claim 6 wherein saidat least one other vinyl resin is selected from the group consisting of vinyl chloride-vinyl acetate copolymer, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer 111161 polymerized with a dibasic acid, a vinyl chlorlde-vmyl chloride copolymer containinga hydroxy group, polyvinyl butyral, and mixtures of polyvinyl butyral, v1nyl acetate, copolymers of vinyl chloride and acrylonitr le, and vinyl chloride-vinylidene chloride copolymers having a different vinylidene chloride content.

11. The method of making a printed felt base sheet comprising the steps of applying to a felt sheet at least one seal coat and then applying to the seal coat a coating composition comprising a mixture of a solution of an oleoresinous material in a solvent with from 5% to 50%- by weight of a solution containing a vinyl chloride-v nylidene chloride copolymer and at least one other resin 1n a solvent, and then evaporating the solvents at temperatures substantially below 300 F. and below the usual fusion temperatures of vinyl copolymers.

References Cited in the file of this patent UNITED STATES PATENTS 2,380,456 Maier July 31, 1945 2,412,592 Maier Dec. 17, 1946 2,502,457 Heckles Apr. 4, 1950 9,799 Crockett Nov. 14, 1950 2,561,427 Stubblebine Apr. 4, 1950 2,624,682 Hazeltine Jan. 6, 1953 FOREIGN PATENTS 129,677 Australia Oct. 23, 1945 -mhAb UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 2,860,071 November ll, 1958 Samuel A. Cohen et al.

or appears in the-printed specification It is hereby certified that err ng correction and that the said Letters of the above "numbered patent requiri Patent should read as corrected below.

for "916,0 Geon 400" read 16.0 Geon Column 5, line 62, Example I,

r" read Taber column 8, line 400 column 6, line 47', for "Tabo 41, for the claim reference numeral "6" read 9 Signed and sealed this 9th day of June 1959.

SEAL ittestz KARL H. AXLINE Attesting Oflicer ROBERT C. WATSON Commissioner of Patents UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 2,860,071 November 11, 1958 Samuel A. Cohen et al.

It is herebi certified that error appears in the-printed specification of the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column 5, line 62-, Example I, for 916.0 Geon 400" read 16.0 Geon 400 column 6, line 4'7, for "Tabor" read Taber column 8, line 41, for the claim reference numeral "6" read 9 Signed and sealed this 9th day of June 1959.

gSEAL) ttest:

KARL H. AXLINE Attesting Officer ROBERT C. WATSON Commissioner of Patents UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 2,860,071 November ll, 1958 Samuel A. Cohen et al.

It is herebjr certified that error appears in the-printed specification of the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column 5, line 62, Example I, for "916.0 Geon 400" read 16.0 Geon 400 column 6, line 47', for "Tabor" read Taber column 8, line 41, for the claim reference numeral "6" read 9 Signed and sealed this 9th day of June 1959.

SEAL) ttest:

ROBERT c. WATSON KARL H. AXLINE Attesting Officer Commissioner of Patents 

1. THE METHOD OF MAKING A PRINTED FELT BASE SHEET COMPRISING THE STEPS OF APPLYING TO A FELT SHEET AT LEAST ONE SEAL COAT THEN APPLYING TO THE SEAL COAT A PRINTED PAINT COATING COMPOSITION CONTAINING FROM 5% TO 50% BY WEIGHT OF A VINYL RESIN SOLUTION INCLUDING A VINYL CHLORIDEVINYLIDENE CHLORIDE COPOLYMER HAVING A VINYLIDENE CHLORIDE CONTENT OF AT LEAST 20% AND THEN SUBJECTING THE PRODUCT TO MODERATE HEAT SUBSTANTIALLY BELOW 300*F. WITHOUT FUSING THE VINYL RESIN. 